Methods and apparatus for improving winding balance on inductive devices

Abstract

Improved balance winding of electronic components including common-mode chokes and methods for using and manufacturing the same. In one embodiment, the common-mode choke includes a core and a pair of windings. The first winding and the second winding are alternatingly wound around the core with each respective winding being flipped at least once over the traverse direction of the winding barrel of the core. In one variant, the number of flips is dependent upon the core geometry, number of windings, and/or the specification limits on electrical balance. In another variant, the windings are first twisted and/or braided prior to being wound onto the winding barrel of the core.

1 .- 20 . (canceled) 
     
     
         21 . A common-mode choke, comprising:
 a core comprising a winding barrel with two flanges disposed at opposing ends of the winding barrel;   a first winding; and   a second winding;   wherein at least the first winding and the second winding are twisted about each other to produce a twisted winding; and   wherein the twisted winding is wound around the winding barrel.   
     
     
         22 . The common-mode choke of  claim 21 , wherein ends of the first winding are secured to respective first terminations resident on each of the two flanges, and ends of the second winding are secured to respective second terminations resident on each of the two flanges. 
     
     
         23 . The common-mode choke of  claim 22 , wherein the respective first and second terminations are each disposed on respective ones of a plurality of corners of the two flanges. 
     
     
         24 . The common-mode choke of  claim 22 , wherein:
 the two flanges are each approximately rectangular in shape;   the two approximately rectangular shaped flanges are disposed in a common angular orientation relative to a central axis of the winding barrel; and   the first termination and second termination on each of the two flanges are disposed on a common side of the respective flange such that the common-mode choke can be surface mounted to a substrate with each of the first and second terminations disposed away from the substrate.   
     
     
         25 . The common-mode choke of  claim 21 , wherein the twisted winding wound around the winding barrel comprises at least one additional winding is twisted with the first and second windings. 
     
     
         26 . The common-mode choke of  claim 21 , wherein the twisted winding is associated with an electrical coupling that is more balanced as compared to a winding that is not twisted. 
     
     
         27 . The common-mode choke of  claim 21 , wherein the core comprises an I-shaped magnetically permeable core. 
     
     
         28 . An inductive device, comprising:
 a magnetically permeable core, the magnetically permeable core comprising a first flange, a second flange, and a central element disposed between and connecting the first and second flanges; and   a braided winding wound around the central element, the braided winding comprising a first winding and a second winding braided together.   
     
     
         29 . The inductive device of  claim 28 , wherein each end of the first and second windings of the braided winding is secured to a respective termination on the first and second flanges, the respective termination being one of four corresponding terminations. 
     
     
         30 . The inductive device of  claim 28 , wherein the braided winding comprises at least a third winding braided with the first and second windings. 
     
     
         31 . The inductive device of  claim 30 , wherein the first, second and third windings are comprised of a primary sub-group and a secondary sub-group; and
 wherein at least said primary and secondary sub-groups are at least partly braided such that at least a portion of the braided windings reside on at least three distinct levels relative to the central element.   
     
     
         32 . The inductive device of  claim 30 , wherein the first, second and third windings are braided together over a given length;
 wherein the first, second and third are comprised of a plurality of braided portions and a plurality of braided portions; and   wherein at least one of the non-braided portions resides between two adjacent braided portions   
     
     
         33 . The inductive device of  claim 28 , wherein the braided winding is associated with an electrical coupling that is more uniform as compared to a non-braided winding made from the first winding and the second winding. 
     
     
         34 . A common-mode choke, comprising:
 a core element comprising a winding barrel with two flanges disposed at opposing ends of the winding barrel;   a first twisted winding comprising a first pair of windings twisted about each other; and   a second twisted winding comprising a second pair of windings twisted about each other;   wherein the first and second twisted windings are alternatingly wound about a first portion of the winding barrel in a given order; and   wherein the first and second twisted windings are wound about second portion of the winding barrel in another order that is opposite of the given order.   
     
     
         35 . The common-mode choke of  claim 34 , wherein the first and second twisted windings are disposed in a single layer around the winding barrel. 
     
     
         36 . The common-mode choke of  claim 34 , wherein the first and second portions of the winding barrel are adjacent to each other, and the other order is caused by a flip of the given order of the winding of the first and second twisted windings. 
     
     
         37 . The common-mode choke of  claim 36 , wherein the first and second twisted windings are alternatingly wound about a third portion of the winding barrel in the given order, the third portion and the second of the winding barrel being adjacent to each other. 
     
     
         38 . The common-mode choke of  claim 34 , wherein, based on a plurality of flips of the first and second twisted windings, the first and second twisted windings are wound in the given order along a first plurality of portions of the winding barrel and the other order along a second plurality of portions of the winding barrel, each of the first and second plurality of portions alternating along the winding barrel. 
     
     
         39 . The common-mode choke of  claim 34 , wherein the twisted winding is associated with an electrical coupling that is more balanced as compared to a winding that is not twisted. 
     
     
         40 . The common-mode choke of  claim 34 , wherein at least one of the first and second twisted windings comprises at least another winding twisted with the corresponding first and second pair of windings.